JP6141440B2 - Mold stator, mold motor and air conditioner - Google Patents

Description

  The present invention relates to a mold stator, a mold electric motor, and an air conditioner.

  Conventionally, a molded electric motor has been adopted as an indoor unit fan motor or an outdoor unit fan motor of an air conditioner. In this mold motor, a stator is molded with a mold resin to form an outer shell, and a rotor is freely arranged on the inner peripheral side of the outer shell. Wiring lead-out parts for drawing out the lead wires from the stator and the wiring board are attached to the mold motor. And this wiring lead-out component is integrally formed with mold resin together with the stator and wiring components.

  However, in the case of such a structure, water easily enters from the gap or interface between the outer shell of the molded motor and the wiring lead part, or the gap or interface between the wiring lead part and the lead wire. Therefore, conventionally, there has been a problem that secondary processing such as application of a sealing material and application of a tape is required as a measure for ensuring the waterproofness.

  The conventional electric motor shown in the following Patent Document 1 includes a lead wiring component so that water does not reach the substrate after the stator is molded. A substrate on which electronic components are mounted can be assembled to the lead wire wiring component, and the lead wire wiring component is installed on the stator. Further, the lead wire wiring component is configured to route a power supply lead wire that supplies power to the stator and a sensor lead wire that supplies power to the substrate and supplies position information of the rotor to the substrate. .

  Further, in the conventional electric motor shown in Patent Document 2 below, the stator is molded with a mold resin to form an outer shell, and a bushing (leading portion) for drawing out a lead wire from the outer shell of the molded motor is formed integrally with the outer shell. Is done. This electric motor is characterized in that the bushing (outlet portion) is an elastic body, and the bushing (outlet portion) is molded and compressed into the outer shell, so that ingress of water from the outlet portion can be suppressed.

JP 2010-273525 A JP 2009-112067 A

  However, in the stator of the conventional mold motor shown in the above-mentioned Patent Document 1, the wiring lead-out portion is formed integrally with the lead wire wiring component, and is further installed on the outer peripheral side of the stator core. Therefore, a connecting portion is formed between the wiring lead portion and the lead wire wiring component, and an interface between the connecting portion and the mold material becomes a water intrusion path. Accordingly, the connecting portion serves as a water immersion path for water that has entered from the wiring lead-out portion, and this water reaches the substrate and the stator. When water reaches the substrate, the water accumulates between the power supply lead wire and the substrate, and when the substrate is energized, pattern corrosion of the substrate occurs and pattern breakage occurs. This makes it difficult to detect the rotor position, and there is a problem that the electric motor may become inoperable. In addition, when the wiring lead portion and the lead wire wiring component are separated, the positioning of the wiring lead portion may become unstable.

  Further, in the conventional molded motor stator shown in Patent Document 2, since the bushing material is an elastic body, there is a problem of environmental resistance such as deterioration of the bushing material in a poor environment.

  This invention is made | formed in view of the above, Comprising: It aims at obtaining the mold stator, mold motor, and air conditioner which can aim at the further improvement of quality.

  In order to solve the above-described problems and achieve the object, the present invention is a mold stator that includes a stator and a substrate on which a rotor position detection circuit is mounted, and has an outer shape formed in a mold resin. A donut-shaped lead wire wiring component attached to one end of the stator in the axial direction, wiring a power supply lead wire to the winding of the stator, and wiring a sensor lead wire to the position detection circuit; A lead part that is provided outside the lead wire wiring part and feeds the power lead wire and the sensor lead wire to the outside of the mold stator, and a power lead wire that is assembled to the lead part and holds the power lead wire A holding part and a sensor lead wire holding part that is assembled to the lead part and holds the sensor lead line, and the lead part includes the sensor lead line. Is connected to the engaging portion for stopping relates the lifting part, characterized in that it comprises a substantially vertical flat portion on the radially outer side with respect to the radial direction of the stator.

  According to the mold stator according to the present invention, since the molding pressure applied to the lead-out component during molding increases, the lead-out component is pressed in the radial direction with a stronger force and comes into contact with the mold die. There is an effect that positioning is possible.

FIG. 1 is a perspective view of a stator assembly of an electric motor according to an embodiment of the present invention as viewed from the substrate side. FIG. 2 is a perspective view of the lead wire wiring component. FIG. 3 is a perspective view of the lead wiring component shown in FIG. 2 as viewed from the opposite side. FIG. 4 is an enlarged view of the lead wire terminal holding portion. FIG. 5 is an enlarged view of the lead-out component and its periphery. FIG. 6 is an enlarged view of the substrate holding portion and its periphery. FIG. 7 is an enlarged view of the substrate holding portion and its periphery. FIG. 8 is a perspective view of the sensor substrate. FIG. 9 is a perspective view of the lead wire wiring component in a state where the power supply lead wire is routed. FIG. 10 is a perspective view of a power supply lead wire holding component. FIG. 11 is a perspective view of a sensor lead wire holding component. FIG. 12 is a perspective view of the mold stator. FIG. 13 is a perspective view of a molded electric motor. FIG. 14 is a side view of the molded motor. FIG. 15 is a diagram illustrating a manufacturing process of a molded electric motor. FIG. 16 is a configuration diagram of an air conditioner incorporating a molded electric motor.

  Hereinafter, embodiments of a mold stator, a mold motor, and an air conditioner according to the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the embodiments.

Embodiment.
FIG. 1 is a perspective view of a stator assembly of an electric motor according to an embodiment of the present invention as viewed from the substrate side. FIG. 2 is a perspective view of the lead wire wiring component shown in FIG. FIG. 3 is a perspective view of the lead wiring component shown in FIG. 2 as viewed from the back surface (opposite surface). FIG. 4 is an enlarged view of a lead wire terminal holding portion provided in the lead wire wiring component shown in FIG. FIG. 5 is an enlarged view of the lead part and the periphery thereof provided in the lead wire wiring part shown in FIG. FIG. 6 is an enlarged view of the substrate holding portion and its periphery provided in the lead wire wiring component shown in FIG. FIG. 7 is an enlarged view of the substrate holding portion and its periphery when viewed from a direction different from FIG. FIG. 8 is a perspective view of the sensor substrate. FIG. 9 is a perspective view of the lead wire wiring component in a state where the power supply lead wire is routed. FIG. 10 is a perspective view of the power supply lead wire holding component. FIG. 11 is a perspective view of the sensor lead wire holding component. FIG. 12 is a perspective view of the mold stator. FIG. 13 is a perspective view of a molded electric motor. FIG. 14 is a side view of the mold motor. FIG. 15 is a diagram illustrating a manufacturing process of a molded motor. FIG. 16 is a configuration diagram of an air conditioner incorporating a molded electric motor.

  The stator assembly 30 shown in FIG. 1 includes an annular stator 10, a lead wire wiring component 1 assembled to the stator 10 at one axial end of the stator 10, and a lead wire wiring component 1. A substrate 11 to be attached and a lead wire assembly 40 are provided.

  The stator 10 includes a stator core 82 in which electromagnetic steel plates are punched into a strip shape and laminated in the axial direction of a shaft 72 (see FIG. 13) of a rotor (not shown) by caulking, welding, adhesion, and the like. The insulating portion 83 and a winding 84 formed by winding a magnet wire around the insulating portion 83 are configured.

  The insulating portion 83 is formed by integrally molding a thermoplastic resin such as PBT (polybutylene terephthalate) with the stator core 82 or by assembling the stator 10 after the molding. The insulating portion 83 is provided with a plurality of pins 81 protruding to the substrate 11 side and a plurality of terminals 12 to which power from the outside is supplied.

  One end of the magnet wire is drawn around the hook portion 85 of the terminal 12 and joined by fusing or soldering. On the other hand, the terminals of all phases are put together to form a neutral point.

  In the following description, the outer side of the end surface in the axial direction of the stator core 82, that is, the side including the terminal 12 is referred to as a connection side, and the opposite side is referred to as an anti-connection side.

  The insulating outer wall 83a constituting the insulating portion 83 prevents the winding 84 from falling to the outer peripheral side of the stator core 82, and the lead wire wiring component 1 is fixed to the axial end portion on the connection side of the insulating outer wall 83a. A plurality of pins 81 for attachment to the child 10 are provided.

  The insulating inner wall 83b that constitutes the insulating portion 83 prevents the winding 84 from falling to the inner peripheral side of the stator core 82, and the stator assembly 30 is provided at the axial end of the insulating inner wall 83b on the opposite side of the connection. When molding, a protrusion (not shown) is provided that is held against the die core part in the axial direction.

  The axial end of the insulating outer wall 83a is formed so that its height is slightly higher than the maximum height of the winding 84 in the axial direction. The winding 84 is formed such that its height in the axial direction decreases as it goes from the insulating outer wall 83a toward the insulating inner wall 83b. In this configuration, when the height of the protrusion (not shown) on the anti-connection side of the insulating inner wall 83b is the same as the height of the axial end portion of the insulating outer wall 83a, a sufficient distance to the winding 84 is ensured. be able to. Therefore, when the stator 10 is installed on the die core part with the anti-connection side of the stator 10 facing down, the stator 10 is stably placed without the winding 84 hitting the mold core part. be able to. As a result, productivity is improved and quality is improved.

  The lead wire assembly 40 includes a power lead 8 that supplies power to the winding 84, a sensor lead 7, and a board-in connector 80 connected to the end of the sensor lead 7. . The board-in connector 80 is connected to the terminal of the sensor lead wire 7 on the side that is inside the mold when the stator 10 is molded.

  An electronic component such as a Hall IC 34 is mounted on the substrate 11 as a rotor position detection circuit (see FIG. 8). The board-in connector 80 is installed on the side opposite to the stator of the board 11, and a terminal (not shown) provided on the board-in connector 80 is inserted into a board through a terminal insertion hole (not shown) formed in the board 11. 11 on the side of the stator. Since the terminal insertion hole is connected to the wiring pattern on the board 11, the terminal provided on the board-in connector 80 is soldered to the terminal insertion hole, so that the sensor lead wire 7 is connected to the electronic on the board 11. Electrically joined to the part.

  The sensor lead wire 7 and the power supply lead wire 8 are wired using the lead wire wiring component 1. Further, the sensor lead wire 7 and the power supply lead wire 8 are a lead wire lead consisting of a power supply lead wire holding component 4 (see FIG. 10), a sensor lead wire holding component 5 (see FIG. 11) and a lead-out component 6 (see FIG. 5). The positional relationship with the lead wiring component 1 is maintained by the portion 2 (see FIG. 1).

  Next, the lead wire wiring component 1 will be described. The lead wire wiring component 1 is formed into a substantially donut shape using a thermoplastic resin such as PBT (see FIG. 2). As shown in FIG. 2, a plurality of mounting legs 13 to the stator 10 are provided on the outer periphery of the lead wire wiring component 1. Each attachment foot 13 has a hole 13a for inserting a pin 81 for attaching a lead wire wiring component provided in the insulating portion 83 of the stator 10. When assembling the lead wire wiring component 1 to the stator 10, the mounting foot 13 comes into contact with the wiring component installation surface of the insulating portion 83 of the stator 10 to perform axial positioning. At this time, the pin 81 of the insulating portion 83 is inserted into the hole 13a of the mounting foot 13 so that the lead wire wiring component 1 is positioned in the rotational direction. In a state where the positioning is completed, that is, in a state where the pin 81 of the insulating portion 83 is inserted into the hole 13a of the mounting foot 13, the lead wire wiring component 1 and the stator 10 are fixed by ultrasonically welding the pin 81, for example. The

  The lead wire wiring component 1 has a predetermined height and a predetermined width from the mounting foot 13 adjacent to the lead wire lead-out portion 2 (see FIG. 1) arranged on the outer diameter side of the stator 10 toward the lead wire lead-out portion 2. The wall part 16 is provided. When the lead wire wiring component 1 is assembled to the stator 10, the wall portion 16 has a flat surface that is substantially perpendicular to the radial direction of the stator (the direction toward the central axis of the stator 10) on the radially outer side. ing. By providing the wall portion 16, it is possible to prevent the melted pin 81 of the insulating portion 83 from flowing out in the radially outward direction of the stator 10 during the ultrasonic welding operation for fixing the stator 10 and the lead wire wiring component 1. . As a result, it is possible to suppress the melted pin 81 of the insulating portion 83 from appearing outside the mold stator, and the quality can be improved. Further, the flow of the resin around the lead wire lead-out portion 2 is adjusted when the stator 10 is molded, the resin pressure to the lead wire lead-out portion 2 can be further increased, and the quality can be improved. Further, the wall portion 16 can be used for positioning a jig during lead wire assembly, and the workability of the lead wire assembly can be improved.

  The wiring of the power supply lead 8 will be described. The power supply lead wire 8 is routed to the terminal 12 of the stator 10 along the lead wire wiring component 1 via the lead wire lead-out portion 2. That is, the three-phase power lead wires constituting the power lead wire 8 are respectively routed to the terminals 12 of the stator 10 arranged at approximately 120 °. The three-phase power supply lead wire is positioned by contacting the terminal with the sheath peeled off against the wall of the lead wire terminal holding portion 14 and when the lead wire wiring component 1 is assembled to the stator 10. It is routed along the surface (lead wire wiring surface 21) of the component 1 on the stator 10 side and the wall (wall 22) provided on the inner periphery (see FIG. 3). The wall 22 is provided with a plurality of protrusions 22a for preventing the positional deviation of the power supply lead 8. Further, the power supply lead wire 8 is bent in the direction of the lead-out component 6 by a lead wire folding pin 27 provided in the vicinity of the lead-out component 6 and drawn, and a power supply lead wire holding projection (in the vicinity of the lead-out component 6 ( (Not shown). Note that the lead wire folding pin 27 is a protrusion having a role of preventing the positional deviation of the lead wire.

  Of the three lead wire folding pins 27, the two lead wire folding pins 27 at both ends are formed higher by a predetermined height than the center pin. Thereby, it is possible to prevent the power supply lead wire from being displaced in the axial direction in the vicinity of the lead wire lead-out portion, and to improve the quality.

  The three power supply lead wires 8 are routed to different lead wire terminal holding portions 14 via power supply lead wire holding portions formed by the lead-out component 6 and the power supply lead wire holding component 4 provided in the lower part thereof. The The power supply lead wire 8 routed to the lead wire terminal holding portion 14 (first lead wire terminal holding portion) farthest from the lead component 6 is routed to the central groove (see FIG. 3) provided in the lead component 6. Further, it is routed to the first lead wire terminal holding portion. The power supply lead wires 8 wired to the lead wire terminal holding portions 14 (second lead wire terminal holding portions) on both sides of the lead-out component 6 are respectively drawn into the outer grooves (see FIG. 3) provided in the lead-out component 6. And is further routed to the second lead terminal holding portion. Here, one of the two power supply lead wires 8 wired to the second lead wire terminal holding portion is routed outside the power supply lead wire 8 wired to the first lead wire terminal holding portion. (See FIG. 9). FIG. 9 is a diagram showing the lead wire wiring component 1 (stator side) in a state where the power supply lead wire 8 is routed.

  The core wires of the power supply lead wires 8 that have been stripped are fixed to the core wire holding portions 24 that are separated from the respective lead wire terminal holding portions 14 when the lead wire wiring components 1 are assembled to the stator 10. The terminal 12 of the child 10 and the core wire are held so as to be close to each other (see FIG. 4).

  Further, in order to secure a space for the electrode that sandwiches the terminal 12 and the core wire, an electrode escape recess 23 is provided in the lead wire wiring component 1. The space of the electrode that sandwiches the terminal 12 and the core wire is necessary for the work of spot welding the core wire and the terminal 12 performed after the lead wire wiring component 1 is assembled to the stator 10. Since the recess 23 is provided, the power supply lead 8 is routed further to the stator 10 side than the lead wire wiring surface 21 (see FIG. 3) of the lead wire wiring component 1. Further, a misalignment prevention protrusion 25 is provided near the electrode escape recess 23. The misalignment prevention projection 25 positions the power supply lead 8 in the axial direction.

  In addition, as shown in FIG. 2, the lead wire wiring component 1 includes a plurality of substantially trapezoidal pedestals 19 on the surface opposite to the stator. When the end surface on the side opposite to the stator of the pedestal 19 abuts on the mold during molding, the stator assembly 30 can be positioned in the axial direction. Moreover, by making the base 19 into a substantially trapezoidal shape, the area where the base 19 is exposed to the outside of the mold stator can be reduced, and the buckling strength of the base 19 can be increased.

  Moreover, the lead wire wiring component 1 includes a positioning portion 18 used for positioning at the time of molding performed after being attached to the stator 10 (see FIGS. 2 and 3). The positioning portion 18 is located inside the inner diameter of the stator 10 in a state where the lead wire wiring component 1 is attached to the stator 10 and is the stator assembly 30, and performs positioning in the radial direction of the mold die. It is provided at a predetermined position corresponding to a pin or a protrusion protruding from the shaft. The positioning portion 18 has an insertion hole 18a, and the stator assembly 30 can be positioned in the rotational direction by inserting a pin or a protrusion protruding from the center shaft for positioning the mold in the radial direction into the insertion hole 18a. Made. At this time, the lead part 6 fixed to the mold and the lead wires (sensor lead wire 7 and power supply lead wire 8) of the stator assembly 30 are positioned on substantially the same straight line. Positioning on substantially the same straight line prevents the stator 10 from being set in the mold so as to be displaced in the rotational direction, thereby preventing the angle with the lead part 6 from being shifted, and the sensor lead wire 7 is pulled to form the substrate. It can suppress that a load is applied to 11 solder parts. The positioning portion 18 further serves as a rotation stopper when a force in the rotation direction is applied to the stator 10 by resin pressure during molding.

  The positioning portion 18 may be provided on the donut-shaped main body 1a of the lead wire wiring component 1, or may be provided connected to the main body 1a as shown in FIGS. In the case of being connected from the main body 1a, the positioning portion 18 is deformed by the resin pressure during the molding from the main body 1a to the positioning portion 18 of the lead wire wiring component 1, and the mold inner diameter side Can be suppressed, and quality can be improved.

  Further, the positioning portion 18 of the lead wire wiring component 1 is provided with a protrusion 18b having a predetermined height that is in contact with the end surface in the axial direction of the center shaft for positioning in the radial direction of the mold on the anti-connection side (stator side). (See FIG. 3). By providing the protrusion 18b, the protrusion 18b comes into contact with the axial end surface of the center shaft during molding, and positioning in the axial direction is performed. Thereby, it can suppress that the positioning part 18 deform | transforms with the resin pressure in shaping | molding, and it exposes to a mold internal diameter part side, and can improve quality.

  Further, the positioning portion 18 of the lead wire wiring component 1 is provided at a position facing a substrate holding portion 15 described later. For example, when the mold motor configured to include the stator assembly 30 according to the present embodiment is installed axially with respect to the outdoor unit of the air conditioner, the lower side is used to prevent flooding of the mold motor. Attach so that the lead-out part 6 comes. In that case, since the positioning unit 18 is disposed on the upper side of the outdoor unit, when water enters the mold motor, water from the surface that is in contact with the center shaft of the mold during molding is suppressed. Can improve quality.

  In addition, a substrate holding portion 15 including a claw portion 31 and a groove portion 32 for assembling the substrate 11 is provided on the inner peripheral side of the stator 10 of the lead wire wiring component 1 (FIGS. 3 and 6). Refer to FIG. A substrate 11 (see FIG. 8) on which a rotor position detection circuit is mounted is assembled to the substrate holder 15. As shown in FIG. 8, the substrate 11 has a substantially rectangular shape with chamfered diagonal corners, and includes a groove portion 35 for locking the lead wire wiring component 1 on one long side, and the other length. The side is provided with a notch portion 36 that is partially cut out so as to be positioned when assembled to the lead wire wiring component 1.

  Further, the board holding part 15 of the lead wire wiring component 1 includes a claw part 31 to be engaged with the groove part 35 of the board 11 and a groove part into which a long side part of the board 11 is cut out when the board 11 is assembled. 32. By fitting the notch portion 36 of the substrate 11 and the groove portion 32 of the substrate holding portion 15, it is possible to suppress the movement and deformation of the lead wire wiring component 1 and the substrate 11 due to the molding pressure during molding. The quality of the electric motor can be improved. Further, the substrate 11 is assembled to the lead wire wiring component 1 by inserting the long side of the substrate 11 that is notched into the groove 32 provided in the substrate holding portion 15 of the lead wire wiring component 1, whereby the substrate 11 is attached to the lead wire wiring component 1. The wiring component 1 can be easily assembled. Since it is not necessary to carelessly position the substrate 11 with the above structure, the area of the substrate 11 can be reduced, the number of substrates 11 can be increased, and the cost of the motor can be reduced.

  At the time of manufacture, after the board 11 is assembled, the board 11 and the board-in connector 80 of the sensor lead wire 7 are joined by soldering. The sensor lead wire 7 is routed toward the lead-out component 6 on the surface opposite to the surface on which the power supply lead of the lead-out component 6 is wired.

  As shown in FIGS. 2 and 5, the claw portion 31 for assembling the substrate 11 is connected to the donut-shaped main body 1 a of the lead wiring component 1 by a plurality of thin-walled connecting portions 28. Therefore, the molding pressure that the substrate 11 receives during molding can be dispersed.

  The thin-walled connecting portion 28 includes a protrusion 29 that protrudes toward the anti-stator side, and the protrusion 29 comes into contact with the mold during molding, so that the substrate 11 can be positioned in the axial direction and prevented from being displaced (see FIG. 2, see FIG.

  As shown in FIG. 5, the lead-out component 6 includes a protrusion 17 as a flat portion extending from the circumferential end toward the lead wire component 1 by a predetermined length in the circumferential direction. When the lead wire wiring component 1 is assembled to the stator 10, the protrusion 17 has a flat surface on the radially outer side that is substantially perpendicular to the radial direction of the stator (the direction toward the central axis of the stator 10). Yes. By providing the protrusions 17, the projected area in the radial direction of the lead part 6 increases, and the radial molding pressure applied to the lead part 6 during molding is also increased. By increasing the molding pressure in the radial direction, the wiring component is pressed in the radial direction with a force stronger than before, and as a result, the radial positioning can be performed by contacting the mold die.

  Further, the lead-out component 6 holds a locking portion 26a for holding two types of lead wire holding components, that is, a locking portion 26a for holding the power supply lead wire holding component 4, and a sensor lead wire holding component 5. And an anchoring portion 26b. The protrusion 17 is connected to the retaining portion 26b.

  The power supply lead wire holding component 4 shown in FIG. 10 includes a foot 41 hung on the locking portion 26 a of the lead-out component 6 and a rib 42, and a protrusion 41 a is provided at the tip of the foot 41. The protrusion 41a contacts the retaining portion 26a, whereby the power supply lead wire holding component 4 is positioned in the axial direction. After the power supply lead wire 8 is wired to the lead-out component 6, the power supply lead wire holding component 4 is assembled with the foot 41 being latched to the latching portion 26 a of the lead-out component 6. When the power supply lead wire holding component 4 is locked to the lead-out component 6, the rib 42 abuts on the lead-out component 6, thereby suppressing the amount of the opening where the power lead 8 is exposed to the outside of the lead wire lead-out portion 2. be able to. Further, a notch 41b is provided on the opposite side of the foot 41 from the protrusion 41a. When the power supply lead wire holding component 4 is locked to the lead-out component 6, the notch portion 41 b reaches the sensor lead wire holding component 5 side beyond the lead-out component 6, and a plurality (five) of sensor lead wires 7 exist. Among these, it acts as a guide for maintaining the circumferential position of the two sensor lead wires 7 wired outside the lead part 6.

  The sensor lead wire holding component 5 shown in FIG. 11 includes an L-shaped foot 51 that is hung on the retaining portion 26 b of the lead-out component 6. After the sensor lead wire 7 is wired to the lead portion 6, the sensor lead wire holding component 5 is locked and assembled to the lock portion 26 b of the lead portion 6.

  In the stator assembly 30 of the present embodiment, the sensor lead wire 7 and the power supply lead wire 8 are routed on the respective surfaces of the lead wire wiring component 1. That is, the sensor lead wire 7 is routed on the surface on the side opposite to the stator of the lead wire wiring component 1 (the side shown in FIG. 2), and the power supply lead 8 is connected to the stator side of the lead wire wiring component 1 (FIG. 3). Route on the side indicated on the side. As a result, the assembly is facilitated, the cost for the assembly can be reduced, and the quality can be improved as the assembly is facilitated. In addition, since the power supply lead 8 is held by the protrusion 22a provided on the surface on the stator side to prevent axial displacement, the quality can be improved.

  Further, the lead wire wiring component 1 has two types of locking portions 26 a and 26 b, the locking portion 26 a holds the power supply lead 8, and the locking portion 26 b holds the sensor lead wire 7. Therefore, it is possible to firmly assemble each lead wire to the lead wire wiring component 1, and the quality can be improved along with the improvement in reliability. Further, by using the foot 41 (notch portion 41b) of the power supply lead wire holding component 4 for holding the sensor lead wire 7, the assembly can be facilitated and the cost can be reduced. In addition, the quality can be improved as the assembly becomes easier.

  The lead wire wiring component 1 in which the sensor lead wire 7 and the power supply lead wire 8 are wired in the above configuration is assembled to the stator 10 of the motor, and the stator protrudes from the mounting foot 13 of the lead wire wiring component 1. When the pin 81 of the insulating portion 83 is fixed by performing thermal welding, ultrasonic welding, or the like, the stator assembly 30 in which the sensor lead wire 7 and the power supply lead wire 8 are assembled is obtained (FIG. 1). .

  Further, when the stator assembly 30 shown in FIG. 1 is molded with a thermosetting resin mold resin such as BMC (bulk molding compound), the mold stator 60 shown in FIG. 12 is obtained. Further, by incorporating a rotor (not shown) and a bracket 74 into the opening 62 of the mold stator 60, the mold motor 70 shown in FIGS. 13 and 14 is obtained.

  Since the lead wire wiring component 1 and the lead-out component 6 are separate parts and are separated by a predetermined distance, the wall portion 16 provided in the lead wire wiring component 1 and the protrusion 17 provided in the lead-out component 6 are also separated. . Therefore, since it is possible to suppress the intrusion of moisture transmitted through the interface between the lead wire lead portion 2 and the mold resin, the quality of the stator 10 can be improved.

  When the mold stator 60 is molded, the lead wire lead-out portion 2 of the stator assembly 30 is pushed outward from the center of the stator 10 by the molding pressure. Therefore, the position of the lead wire lead-out portion 2 is maintained without contacting the stator core 82. Therefore, the lead wires are not fixed in contact with each other at the time of molding, and no gap is generated at the portion where the lead wires come into contact. Therefore, the water that has entered from the gap or interface between the lead wire lead-out portion 2 and the mold resin does not travel through the gap between the lead wires and reach the substrate 11. As a result, the quality of the mold stator 60 can be improved.

  Further, when the stator 10 is installed on the mold, the protrusion (not shown) formed on the side opposite to the insulating inner wall 83b is supported by the installation part formed on the mold. This installation part is, for example, a stepped part having an outer diameter slightly larger than the inner diameter dimension of the stator core 82, a plurality of claws extending in a protruding manner from the opening part installation surface of the die core part to the stator 10, A plurality of protrusions that extend from the bracket installation surface in the vicinity of the die core part and not connected to the inner diameter of the stator core 82.

  Thus, since the stator 10 is supported by the installation part of a metal mold | die, it is not necessary to support the outer peripheral part of the stator 10 by a metal mold | die (regulation member) at the time of molding. Therefore, no boundary surface between the stator core 82 and the mold resin is formed on the outer periphery of the mold stator 60.

  Further, when the stator 10 is supported by the protrusions of the mold, even when the mold stator 60 is installed in the mold, the protrusions (not shown) formed on the side of the insulating inner wall 83b opposite to the connection side are the stator cores 82. It is no longer exposed to the inner diameter side, and the effect of suppressing water ingress can be further enhanced.

  13 and 14, a rotor shaft 72, a waterproof cap 71, and an E ring 73 are assembled to the mold stator 60 using a bracket 74. The waterproof cap 71 is for preventing water from entering between the shaft 72 and the bracket 74. As a result, a molded electric motor 70 is obtained that has good productivity, is accompanied by good quality, and can reduce costs.

Next, the manufacturing process of the mold motor 70 will be described with reference to FIG.
(1) Step 1: The stator core 82 is manufactured. In addition, the lead wire wiring assembly 40 and the lead wire wiring component 1 are manufactured.
(2) Step 2: Winding 84 is applied to the stator core 82. In addition, the power supply lead wire 8 of the lead wire wiring assembly 40 is wired to the lead wire wiring component 1. At this time, the core wire of the power supply lead wire 8 is routed to the core wire holding portion 24. In addition, the power supply lead wire holding component 4 is manufactured.
(3) Step 3: Assemble the power supply lead wire holding component 4 to the lead wire wiring component 1. In addition, the substrate 11 is manufactured.
(4) Step 4: The substrate 11 is assembled to the lead wire wiring component 1. The terminals of the board-in connector 80 are soldered to the board 11 assembled to the board holding unit 15. In addition, the sensor lead wire holding component 5 is manufactured.
(5) Step 5: Assemble the sensor lead wire holding component 5 to the lead wire wiring component 1.
(6) Step 6: Assemble the lead wire wiring component 1 to the stator 10, heat-weld the pin 81 coming out from the mounting foot 13 of the lead wire wiring component 1, and the core wire of the terminal 12 of the stator 10 and the power supply lead wire 8 Spot welding.
(7) Step 7: The stator assembly 30 is molded to manufacture the mold stator 60. In addition, parts such as a rotor and a bracket 74 are manufactured.
(8) Step 8: A mold motor 70 is manufactured by assembling a rotor or the like to the mold stator 60.

  FIG. 16 shows an air conditioner 100 incorporating a molded electric motor 70 according to an embodiment of the present invention. The air conditioner 100 includes an indoor unit 200 and an outdoor unit 300 connected to the indoor unit 200. The indoor unit 200 and the outdoor unit 300 are provided with a molded electric motor 70 as a drive source for the blower. When the mold motor 70 is installed in the indoor unit 200 and the outdoor unit 300, a plurality of mounting feet 61 (see FIG. 12) extending from the outer peripheral side of the mold stator 60 to the radially outer side are used. Thus, by using the mold motor 70 as a motor for a blower that is a main part of the air conditioner 100, the ingress of water into the stator of the motor for the blower is suppressed, and the air conditioner 100 with good quality at low cost. Can be obtained.

  As described above, the mold stator 60 according to the present embodiment supplies electric power to the substrate 11 on which electronic components constituting the rotor position detection circuit are mounted and the winding 84 of the stator 10. The lead wire wiring component 1 on which the power supply lead wire 8 and the sensor lead wire 7 connected to the substrate 11 are wired, and the lead wire wiring component 1 are provided outside the diameter of the lead wire wiring component 1, and the lead wire is led out of the mold stator 60. A lead part 6 to be attached, a power supply lead holding part 4 that is assembled to the lead part 6 and holds the power lead 8, a sensor lead wire holding part 5 that is attached to the lead part 6 and holds the sensor lead 7, The lead-out component 6 includes a protrusion 17 for increasing the projected area in the radial direction. As a result, the molding pressure applied to the lead part 6 when molding the mold stator 60 is increased, so that the lead part 6 is pressed in the radial direction with a stronger force and comes into contact with the mold die, thereby positioning in the radial direction. Is possible.

  Further, the lead wire wiring component 1 includes a wall portion 16 having a predetermined height and a predetermined width from the mounting foot 13 adjacent to the lead component 6 disposed on the outer diameter side of the stator 10 toward the lead component 6. The flow of the resin around the lead-out component 6 when the mold stator 60 is molded is adjusted. As a result, the force applied to the lead-out component 6 can be further increased, and the radial positioning accuracy of the lead-out component 6 is improved, so that the quality can be improved. Further, since the wall portion 16 is provided, the melted insulating portion (pin 81) is exposed to the outside of the mold stator 60 during the ultrasonic welding operation for fixing the stator 10 and the lead wire wiring component 1. Can be suppressed, and quality can be improved. Moreover, since the wall part 16 can be used as positioning of a jig | tool at the time of lead wire assembly, the workability | operativity of an assembly | attachment can be improved.

  Further, the protrusion 17 in which the lead-out component 6 extends from the circumferential end toward the lead wire wiring component 1 by a predetermined length in the circumferential direction is separated from the wall portion 16 of the lead wire wiring component 1 by a predetermined distance. It is possible to prevent water from entering from the lead-out component 6 and the moisture entering the inside through the interface between the resin portion and the mold to reach the substrate 11 and improve the water immersion resistance.

  In addition, the mold stator concerning embodiment of this invention shows an example of the content of this invention, and it is possible to combine with another another well-known technique, and does not deviate from the summary of this invention. Of course, it is possible to change the configuration such as omitting a part of the range.

  As described above, the present invention is useful as a mold stator, a mold motor, and an air conditioner.

  1 Lead wire wiring component, 1a body, 2 lead wire lead-out part, 4 power supply lead wire holding part, 5 sensor lead wire holding part, 6 lead out part, 7 sensor lead wire, 8 power supply lead wire, 10 stator, 11 substrate, 12 terminal, 13 mounting foot, 13a hole, 14 lead wire terminal holding part, 15 substrate holding part, 16 wall part, 17, 18b, 29, 41a protrusion, 18 positioning part, 18a insertion hole, 19 base, 21 lead wire wiring Surface, 22 Wall, 23 Recessed part, 24 Core wire holding part, 25 Position shift prevention protrusion, 26a, 26b Locking part, 27 Lead wire folding pin, 28 Thin connection part, 30 Stator assembly, 31 Claw part, 32, 35 Groove part , 34 Hall IC, 36 Notch, 40 Lead wire assembly, 41, 51 feet, 42 Rib, 60 Mold stator, 70 Mo Motor, 71 waterproof cap, 72 shaft, 73 E-ring, 74 bracket, 80 board-in connector, 81 pins, 82 stator core, 83 insulating part, 83a insulating outer wall, 83b insulating inner wall, 84 winding, 85 hook part, 100 air conditioner, 200 indoor unit, 300 outdoor unit.

Claims (5)

A mold stator including a stator and a substrate on which a rotor position detection circuit is mounted, and having an outer shape formed in a mold resin,
A donut-shaped lead wire wiring component attached to one end of the stator in the axial direction, wiring a power lead to the winding of the stator, and wiring a sensor lead to the position detection circuit;
A lead part provided outside the diameter of the lead wire wiring component, and leading out the power lead and the sensor lead to the outside of the mold stator;
With
The lead-out component includes a locking portion that holds a sensor lead wire holding component, and a protrusion having a flat portion that is substantially perpendicular to the radial direction of the stator, on the radially outer side .
Wherein the mold stator projections that are disposed between the leadwires wiring component and the engaging portion. The lead wire wiring component has a plurality of mounting legs on the outer periphery for mounting to the stator,
The plurality of mounting feet each have a hole for inserting a fixing pin provided in the stator,
2. The mold stator according to claim 1, wherein two of the plurality of mounting feet, which are provided near both ends of the lead-out component, include wall portions that are substantially perpendicular to the radial direction of the stator. .   The mold stator according to claim 2, wherein the flat portion is provided at a position away from the wall portion.   A mold motor using the mold stator according to claim 1, 2 or 3.   An air conditioner equipped with the molded motor according to claim 4 as a blower motor.

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